Device for measuring gas flow-rate particularly for burners

ABSTRACT

A device for measuring the flow-rate of gas in a duct, particularly for burners. The device includes a gas flow-rate sensor generating a first output signal proportional to the flow-rate detected, a temperature-compensation circuit receiving the first output signal and generating a second output signal proportional to the gas flow-rate detected by the sensor and independent of the temperature of the gas and/or the flow-rate sensor. The compensation circuit has a temperature sensor. The device also includes a calibration circuit receiving the second output signal. The calibration circuit generates a third output signal proportional to the gas flow-rate detected and independent of structural parameters of the flow-rate sensor and/or of the temperature sensor so that the third output signal is correlated with the flow-rate detected and independent of the temperature of the gas, the temperature of the flow-rate sensor, and the structural parameters of the flow-rate sensor.

TECHNICAL FIELD

[0001] The present invention relates to a device for measuring gas-flow-rate, particularly for burners, according to the preamble to the main claim.

TECHNOLOGICAL BACKGROUND

[0002] In known devices, the flow-rate of a gas is generally calculated with the use of a so-called “hot-wire” sensor, that is, a wire resistor which is heated to a predetermined temperature by means of a current and is positioned in the gas-flow. The flow-rate of gas is obtained by means of known physical laws, by measuring the power dissipated by the sensor.

[0003] Since the value of the power dissipated is dependent not only on the flow-rate but also on the temperature of the gas, the signal output by the sensor is generally compensated to take account of the possible variations of this temperature.

[0004] For this purpose, a so-called “cold” sensor, also positioned in the gas-flow, is typically used to measure the temperature thereof.

[0005] However, a temperature-compensating circuit comprising the sensors mentioned is not easy to design and often requires complex circuit arrangements.

[0006] Moreover, the cost of the sensors used is usually quite high since the signal output by the sensor also depends on the constructional characteristics of the sensor itself. In order to obtain the same flow-rate measurement from two devices including two different flow-rate sensors, it is therefore necessary for the two sensors to have very similar characteristics.

[0007] In addition, in devices according to the prior art, the two sensors for measuring flow-rate and temperature are generally positioned in a single probe to be inserted in the duct through which the gas-flow to be measured is flowing. The introduction of this probe causes a pressure drop in the duct which may lead to malfunction of the apparatus to which the gas is supplied.

[0008] The technical problem underlying the present invention is that of providing a flow-rate measuring device, particularly for burners, which is designed structurally and functionally to prevent the problems discussed with reference to the prior art mentioned.

DESCRIPTION OF THE INVENTION

[0009] The present invention solves the problem posed with a flow-rate measuring device formed in accordance with the appended claims.

BRIEF DESCRIPTION OF THE DRAWINGS

[0010] The characteristics and the advantages of the invention will become clearer from the detailed description of a preferred embodiment thereof, described by way of non-limiting example with reference to the appended drawings, in which:

[0011]FIG. 1 is a view in side elevation and in section of a flow-rate measuring device according to the present invention,

[0012]FIG. 2 is a front elevational view of the measuring device of FIG. 1, sectioned on the line II-II,

[0013]FIG. 3 is a block diagram of a measurement circuit included in the measuring device of FIG. 1, and

[0014]FIG. 4 is a more detailed diagram of the circuit represented by the block diagram of FIG. 3.

PREFERRED EMBODIMENT OF THE INVENTION

[0015] With initial reference to FIGS. 1 and 2, a flow-rate measuring device according to the present invention is generally indicated 1.

[0016] The flow-rate measuring device 1 comprises a tubular body 2 through which the gas of which the flow-rate is to be measured flows. The direction of the gas-flow is indicated by the arrow G in FIG. 1. The tubular body 2 is connected to a duct 3 (shown partially) for supplying the gas to a burner of heating apparatus (not shown). The gas flow-rate value obtained by the measuring device 1 as described in detail below is displayed on a display 4 (FIG. 3) preferably incorporated on a timer/thermostat. Moreover, prior to display, the hourly or daily flow is preferably converted, by suitable conversion means, into a consumption value and, in particular, by the introduction of the unit cost of the gas used, into a value indicating a cost sustained per unit of time for the quantity of gas measured by the device 1. Alternatively, the display 4 may be located on a wall or on a control panel of domestic heating apparatus, or in a remote control for the operation of the apparatus and/or of a timer/thermostat.

[0017] The tubular body 2 comprises a shell 5 formed as a Venturi tube and including a converging portion 6, a narrow cross-sectioned portion 7, and a diverging portion 8. A grating 9 of predetermined mesh is positioned at the entry to the converging portion 6, with reference the direction of the gas-flow, perpendicular to the said flow, to even out the vector field of the velocities of the gas-flow passing through the tubular body 2.

[0018] Moreover, a first through-hole 10 and a second through-hole 11 are formed in the shell 5 of the tubular body 2, in alignment with one another in a direction parallel to an axis X of the tubular body 2 and a predetermined distance apart, for housing support means 15, 16 for a first sensor S1 and a second sensor S2, preferably NTC sensors, also known as thermistors, for measuring the speed and the temperature of the gas-flow, respectively. The thermistors S1 and S2 are positioned in a manner such that they are completely enveloped by the gas-flow and are spaced from an internal wall 5 a of the Venturi tube. The first hole 10 is formed in the narrow-sectioned portion 7 of the Venturi tube and the second hole 11 is formed in the converging portion 6.

[0019] The tubular body 2 also comprises a closure plate 12, fixed to the body 2, for example, by means of screws 13, for preventing gas from leaking through the holes 10, 11 and for the fixing of the support means 15, 16 of the thermistors S1, S2. Fluid sealing means such as a gasket 14 are also interposed between the plate 12 and the tubular body 2.

[0020] The measuring device 1 also comprises a measurement circuit 20 the output voltage Vout of which is proportional, in accordance with a main characteristic of the invention, purely to the flow-rate value of the gas-flow and is independent of structural parameters of the sensors S1 and/or S2, except for negligible differences (generally of less than 2% for sensors of the same type). In other words, if the sensor S1 and/or S2 is replaced in the circuit 20, the value of the voltage Vout for a given gas flow-rate does not change.

[0021] The amplitude value of the voltage signal Vout output by the circuit 20 is then converted into a flow-rate value by means of a known curve, as explained below. This flow-rate value is converted again into a consumption value and is then displayed on the display 4.

[0022] The measurement circuit 20 comprises a first circuit 23 which is for keeping the resistance R_(S1) of the thermistor S1 at a constant value and the voltage output signal V_(S1) of which depends both on the gas flow-rate value and on the difference between the temperature of the gas and the temperature of the thermistor S1.

[0023] The circuit 20 also comprises a temperature-compensation circuit 24 for compensating for the above-mentioned dependence of the signal output by the circuit 23 on temperature. The voltage output signal Vc of this circuit 24 depends both on the gas flow-rate value and on the structural parameters of the thermistors S1 and/or S2. A calibration circuit 22 included in the measurement circuit 20 can eliminate the latter above-mentioned dependence.

[0024] The first circuit 23 comprises the hot-wire thermistor S1 which is kept at a temperature (T_(sens)) greater than the temperature of the gas (T_(gas)) in which it is immersed. By known laws of physics, the power dissipated in the thermistor S1 is:

W=I _(S1) ² R _(S1=) V _(S1) ² /R _(S1)=(E+Fv ^(α))ΔT

[0025] from which

V _(S1) ² =f(v)R _(S1) ΔT+PΔT;

[0026] in which E, F and α depend on the structural parameters of the thermistor S1 and on the type of gas used, v is the speed of the gas which is a variable of interest from which the gas flow-rate is obtained directly, and ΔT=T_(sens)−T_(gas).

[0027] As is known, the internal resistance of NTC thermistors is greatly dependent on temperature; in particular, as the temperature of the thermistor increases, its resistance decreases. The power absorbed by the thermistor S1 is also subject to variations with variations of the gas temperature, because of the thermal exchanges between the thermistor S1 and the molecules of the gas in which it is immersed. There may therefore be a variation in the heat-transfer coefficient between gas and sensor so that the voltage across the sensor S1 may also vary if the gas speed remains constant.

[0028] The value of the resistance R_(S1), and hence of the temperature, is kept constant and equal to a predetermined value by means of the first circuit 23, as described by way of example below.

[0029] The thermistor S1 is part of a first resistive bridge network 19 including two branches in parallel with one another, the first branch comprising two resistors R1 and R2 of equal value in series with one another and the second branch comprising the thermistor S1 in series with a resistor R3.

[0030] A terminal of the thermistor S1 and a terminal of the resistor R1 are connected to earth, and a terminal of the resistor R2 and a terminal of the resistor R3 are connected to the emitter of a transistor Q1 the collector of which is connected to a terminal of a supply of a voltage V₊. Moreover, the non-earthed terminal of the thermistor S1 is connected (node Q), via a resistor R4, to the inverting input of an operational amplifier OP1 the non-inverting input of which is connected (node P) to the non-earthed terminal of the resistor R1. The output of the amplifier OP1 is also connected to the base of the transistor Q1.

[0031] Filter means, comprising a capacitor C1 and a first potentiometer P1, are interposed between the output of the amplifier OP1 and the base of the transistor Q1 for introducing a suitable delay in the response of the first circuit 23 to variations in the temperature of the thermistor S1 should these variations be extremely rapid.

[0032] The voltage signal V_(S1) at the terminals of the sensor S1 is applied to the non-inverting input of an operational amplifier OP2 configured as a voltage follower. The output of the follower OP2 is connected to a terminal of a second resistive network 25 comprising the second thermistor S2 (of resistance R_(S2)) which detects the temperature of the gas in which it is immersed. The resistive network 25 which comprises two branches in parallel with one another, the first branch including the thermistor S2 and a resistor R5 and the second branch including a resistor R6, is also connected by its other terminal, via a resistor R7, to the inverting input of an operational amplifier OP3 in the inverting configuration, the output voltage of which is equal to Vc.

[0033] The calibration circuit 22 comprises a third resistive network 26 including a second potentiometer P2 and connected between the terminals of a supply of a voltage V⁻. The potentiometer P2 is connected to the non-inverting input of an operational amplifier OP4 configured as a voltage follower, the output of which is connected, by means of a resistor R8, to the inverting input of an operational amplifier OP5 in differential configuration, to the non-inverting input of which the voltage Vc output by the second circuit 24 is applied, via a resistor R9. The voltage output by the differential amplifier OP5 is applied, via a resistor R10, to the inverting input of an operational amplifier OP6 in inverting configuration, the non-inverting input of which is connected to earth.

[0034] The amplifier OP6 has a gain which is variable with variations in the overall resistance of a fourth resistive network 27 by which the inverting input and the output of the operational amplifier OP6 are connected. The fourth resistive network 27 comprises two branches, a first branch comprising a resistance R11 having a terminal A and an opposite terminal which is connected to a potentiometer P3, and a second branch comprising a resistance R12 having a terminal B, its other terminal being connected in series with the third potentiometer P3. The fourth resistive network 27 also comprises a switch 29. When the switch 29 is connected to the terminal A, a current flows through the first branch of the fourth resistive network 27 and the gain of the amplifier OP6 is unitary (naturally if R11=R10), whereas it adopts a value k, which can be modified by means of the potentiometer P3, when the switch 29 is connected to the terminal B and current flows through the second branch of the resistive network 27. The output voltage Vout of the measurement circuit 20 is present at the output of the amplifier OP6.

[0035] The measurement circuit 20 operates as follows.

[0036] In the circuit 23, the current I_(S1), which passes through the thermistor S1 varies as its temperature varies. The resistors R1-R3 are selected in a manner such that the bridge 19 is in equilibrium when the resistance of the sensor S1 corresponds to a predetermined value. The current variation is compensated as a result of a feedback, so as to bring the temperature back to the predetermined value. More particularly, the voltage VP at the node P is determined by the value of the resistance R_(S1) which initially is fixed and equal to the resistance of the resistor R3. In this condition, VQ-VP=0. When this potential difference varies because of a variation of the resistance R_(S1), the output voltage of the amplifier OP1, which is applied to the base of the transistor Q1, varies. This leads to a variation in the current flowing in the resistive network 19, that is, a variation in the current I_(S1) passing through the thermistor S1, which is thus controlled in a manner such as to bring the temperature of the thermistor S1, or its resistance, back to the value of R3. The voltage VP² is thus proportional to f(v)ΔT.

[0037] The dependence of the voltage VP² on ΔT is compensated by the circuit 24 since variations of the voltage VP due to temperature variations of the gas are compensated by similar variations, in the opposite direction, at the terminals of the second resistive network 25 comprising the second thermistor S2. The voltage applied to the inverting input of the amplifier OP3 and hence also the voltage Vc output thereby is therefore independent of ΔT and depends solely on the speed of the gas flow and on the structural parameters E and F of the thermistor S1 (which change very little with changes of the sensor). For a given v and with variations of E and F, there is therefore a family of curves of known equation which represent the behaviour of the voltage Vc as a function of the speed v. The calibration circuit 22 can obtain from this family a single curve which relates the voltage output by the circuit to the speed, and hence to the flow-rate, of the gas. This curve is valid for whichever thermistor S1 is used, that is, Vout is proportional to V_(out) ² ∝(E*+F* v^(α)) when E* and F* are constant.

[0038] This single curve is obtained operatively by making all of the curves of the family pass through two predetermined points, since it has been shown that all of the other points of each curve are thus also very close to the corresponding points of the other curves of the same family.

[0039] In a first operative condition in which the flow-rate of the gas through the tubular body 2 has a predetermined minimum value Qmin, the switch 29 is brought into contact with the terminal A of the resistive network 27 and the resistance of the potentiometer P2 is varied to achieve a value p for which the output voltage Vout of the circuit 22 is zero. In a second operative condition in which the flow-rate has a predetermined maximum value Qmax, the switch 29 is brought into contact with the terminal B, the resistance of the potentiometer P2 is p, and the resistance of the potentiometer P3 is varied until a gain of the amplifier OP6 of k is obtained, in which condition Vout=V*, where V* is a predetermined constant voltage value. Each curve of the above-mentioned family thus passes through the points (Qmin, 0) and (Qmax, V*).

[0040] Subsequent measurements of Vout in order to obtain the flow-rate of the gas-flow are made whilst the switch is kept in contact with the terminal B, the resistance of the potentiometer is p, and the gain of the amplifier OP6 is k. It is thus possible to attribute to a value of the voltage Vout a single flow-rate value (which can be derived directly from the gas speed) by means the single curve thus obtained and stored, irrespective of the thermistor S1 used (provided that the sensors are of the same type).

[0041] The invention thus solves the problem posed, achieving many advantages over known solutions.

[0042] A first advantage lies in the low production cost of the device according to the invention since, by virtue of the calibration circuit, it is possible to use sensors of very low cost which do not need to have substantially constant constructional characteristics.

[0043] A further advantage is that the measurement of speed and hence of flow-rate is relatively accurate owing to the positioning of the flow-rate sensor in the narrow-sectioned portion of the Venturi tube and to the presence of the grating upstream of the gas-flow enveloping the sensor of the invention.

[0044] Moreover, the diverging portion of the Venturi tube enables limited pressure losses to be achieved.

[0045] Furthermore, the fact that an indication of the hourly or daily gas consumption is displayed on a display provides the user with immediate information which can be used to reduce consumption.

[0046] Not least, the device according to the invention has great structural simplicity, since the temperature-compensation circuit is effective but of simple construction. 

1. A device (1) for measuring the flow-rate of a gas-flow in a duct (3), particularly for burners, comprising: a gas flow-rate sensor (S1) which can generate a first output signal (V_(S1)) proportional to the flow-rate detected, a temperature-compensation circuit (24) to which the first output signal (V_(S1)) is applied and which can generate a second output signal (Vc) proportional to the flow-rate of gas detected by the flow-rate sensor (S1) and independent of the temperature of the gas and/or of the temperature of the flow-rate sensor, the compensation circuit comprising a temperature sensor (S2), characterized in that it comprises: a calibration circuit (22) to which the second output signal (Vc) of the temperature-compensation circuit (24) is applied, the calibration circuit (22) being able to generate a third output signal (Vout) proportional to the gas flow-rate detected and independent of structural parameters of the flow-rate sensor (S1) and/or of the temperature sensor (S2) so that the third output signal is correlated with the flow-rate detected and independent of the temperature of the gas and/or of the temperature of the flow-rate sensor (S1) as well as of the structural parameters of the flow-rate sensor.
 2. A measuring device according to claim 1 in which the flow-rate sensor (S1) and the temperature sensor (S2) are NTC thermistors.
 3. A measuring device according to claim 1 or claim 2 in which the third output signal (Vout) generated by the calibration circuit (22) has a value of substantially zero when the flow-rate of the gas supplied through the duct (3) is at a predetermined minimum value.
 4. A measuring device according to one or more of the preceding claims in which the third output signal (Vout) generated by the calibration circuit (22) and correlated with the maximum flow-rate supplied through the duct (3) is equal to a predetermined maximum value.
 5. A measuring device according to one or more of the preceding claims in which the calibration circuit (22) comprises a first operational amplifier (OP5) in differential configuration, to the inverting input of which a voltage the amplitude of which is variable in a predetermined manner is applied, and to the non-inverting input of which the second output signal (Vc) from the temperature-compensation circuit (24) is applied.
 6. A measuring device according to claim 5 in which the calibration circuit (22) comprises a second operational amplifier (OP4) configured as a voltage follower, the output of which is connected to the inverting input of the first, differential amplifier (OP5) and the non-inverting input of which is connected to a third resistive network (26) of variable overall resistance.
 7. A measuring device according to claim 5 or claim 6 in which the calibration circuit (22) comprises a third operational amplifier (OP6) the inverting input of which is connected to the output of the first, differential amplifier (OP5) the non-inverting input of which is connected to earth and the output voltage of which is equal to the third output signal (Vout) of the calibration circuit (22).
 8. A measuring device according to claim 7 in which the third amplifier (OP6) comprises a fourth resistive network (27) of variable overall resistance, connecting the inverting input and the output of the third amplifier (OP6).
 9. A measuring device according to claim 8 in which the fourth resistive network (27) comprises a first branch and a second branch which are capable of being excluded selectively by a switch (29), the first branch comprising a first resistor (R11) with a resistance value such that, when the switch is connected to the first branch, the gain of the third amplifier (OP6) is unitary, and the second branch comprising a second resistor (R12) in series with a potentiometer (P3) so that, when the switch (29) is connected to the second branch, the gain of the third amplifier (OP6) is equal to a predetermined value.
 10. A measuring device according to one or more of the preceding claims, comprising a first circuit (23) for keeping the temperature of the flow-rate sensor (S1) equal to a predetermined constant temperature value.
 11. A measuring device according to claim 10 in which the first circuit (23) comprises feedback means including a fourth operational amplifier (OP1) the non-inverting input of which is connected to a terminal of the flow-rate sensor (S1) and the output of which is connected to the base of a transistor (Q1), the emitter of the transistor (Q1) being connected to a first resistive bridge network (19) comprising the flow-rate sensor (S1) so that, for variations of a voltage at the terminals of the flow-rate sensor (S1) caused by variations from the predetermined temperature of the flow-rate sensor (S1), there are corresponding corrective variations of a current (I_(S1)) passing through the flow-rate sensor (S1) in order to bring the temperature value of the flow-rate sensor (S1) back to the predetermined temperature value.
 12. A measuring device according to claim 11 in which the temperature-compensation circuit (24) comprises a fifth operational amplifier (OP2) configured as a voltage follower, to the non-inverting input of which the output signal of the flow-rate sensor (S1) is applied and the output of which is connected to a second resistive network (25) comprising the temperature sensor (S2).
 13. A measuring device according to claim 12 in which the second resistive network (25) is such that, for variations of the voltage output by the flow-rate sensor (S1) caused by gas-temperature variations, there are corresponding similar variations, in the opposite direction, of the output voltage of the second resistive network (25), so that the signal output by the second resistive network (25) is independent of temperature.
 14. A measuring device according to one or more of the preceding claims, comprising a tubular body (2) defining a Venturi tube through which the gas flows, the Venturi tube being in fluid communication with the duct (3), the flow-rate sensor (S1) being positioned in a portion (7) of the Venturi tube having a narrow cross-section, and the temperature sensor (S2) being positioned in a converging portion (6) of the Venturi tube.
 15. A measuring device according to claim 14 in which the tubular body (2) comprises a grating (9) of predetermined mesh positioned upstream of the tubular body (2), with reference to the direction of flow of the gas, to even out the field of velocities of the gas.
 16. A measuring device according to one or more of the preceding claims, comprising indicator means (4) for displaying a value correlated with a cost per unit of time of the quantity of gas measured by the device.
 17. A measuring device according to claim 16, comprising means for converting the value of the signal (Vout) output by the calibration circuit (22), which is proportional to the flow-rate of the gas, into the consumption value. 